Downhole telescoping tool with radially expandable members

ABSTRACT

A downhole axial expansion or telescoping tool includes radially expandable tubular members. The tubular members are relatively moveable before and after radial expansion, and include an intermediate layer therebetween of a non-metal or non-cladding material. The intermediate layer may provide any one or more of lubricity, load transfer, sealing, and shape retention during and after radial expansion.

BACKGROUND

This disclosure relates generally to hydrocarbon exploration andproduction, and in particular to forming well bore tubular strings andconnections to facilitate hydrocarbon production or downhole fluidinjection.

During hydrocarbon exploration and production, a well bore typicallytraverses a number of zones within a subterranean formation. A tubularsystem may be established in the well bore to create flow paths from themultiple producing zones to the surface of the well bore. Efficientproduction is highly dependent on the inner diameter of the tubularproduction system, with greater inner diameters producing morehydrocarbons or allowing inserted equipment with appropriate pressureratings to be used in well completions. Existing apparatus and methodsfor producing hydrocarbons include a complex set of tubulars,connections, liner hangers, sand control devices, packers and otherequipment which tend to constrict the inner diameter of the productionsystem available for production.

The tubular system implemented during the treatment, completion andproduction of subterranean oil and gas wells may also include a packerset at a preselected location above a production zone. In the case ofwells of substantial depth, and particularly wells where the downholetemperatures are substantially in excess of or below the surfacetemperatures, problems have been encountered due to excessive expansionor contraction of the elongated tubing string. For example, in thetreatment or stimulation of the well, it is common to introduce fluidsat surface ambient temperature into the tubing string. In some cases,the fluid is introduced as steam at elevated temperatures. When themajor portions of the tubing string are at a much higher temperatureinitially, this inherently results in a cooling, and hence a substantialcontraction of the tubing string, resulting in the production of asubstantial tensile stress in the tubing string between its surfaceconnection and the set packer. Similarly, in the production phase ofsuch wells, the production fluid is normally at a temperaturesubstantially in excess of the temperature of the majority of the tubingstring, resulting in a substantial expansion of the tubing string andthe production of a substantial compressive force on the tubing string.Additionally, changes in fluid pressure inside and outside the tubingstring play a major role in the development of substantial tension orcompressive forces in the tubing string.

In other systems, a tubing hanger assembly is disposed at a relativelyelevated downhole position within the well to suspend the productiontubing extending to the production zones from such tubing hanger.Intermediate the tubing hanger and the top of the well there is commonlyprovided one or more production tubing strings commonly referred to as a“space-out section” which extends to a well surface hanger which isutilized to suspend the tubing string weight intermediate the downholehanger and the surface hanger. The tubing strings coupled to the hangersundergo similar expansion or contraction forces as described.

To address the described expansion or contraction of the downholetubulars, an expansion joint is disposed in the tubing string. Theexpansion joint may be located between the bottom of the tubing stringand the packer. The expansion joint may be located between the surfacehanger and the downhole hanger, or in the space-out section. Theexpansion joint is an axially moveable or telescoping device orcomponent designed to enable relative movement between two fixedassemblies in the event of thermal expansion or contraction. Expansionjoints within the completion assembly prevent any movement or forcesbeing transmitted to fixed components such as packers or tubing hangers.Such expansion joints may, for example, comprise an elongated seal borereceptacle attached to the packer or hanger within which there issealingly telescopically mounted a mandrel connected at its upper end tothe tubing string and relatively movable with respect to the seal boreof the receptacle in response to the changes in tension or compressionin the tubing string. A telescoping joint disposed in a space-outsection may be capable of expansion or contraction to absorb temperatureproduced variations in length of the space-out section or dimensionaldifferences between the planned and actual location of the surfacehanger with respect to the downhole hanger. Further, the telescopingjoint may have rotational or torque transmitting capability so thatrotation can be accomplished through the joint to the right or to theleft in order to perform required operations on various pieces ofapparatus carried by the tubing string.

The principles of the present disclosure are directed to overcoming oneor more of the limitations of the existing apparatus and processes forincreasing fluid injection or hydrocarbon production during treatment,completion and production of subterranean wells.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more detailed description of the embodiments of the presentdisclosure, reference will now be made to the accompanying drawings,wherein:

FIG. 1 is a schematic view of an expandable tubular string disposed in aborehole, the string including expandable tubular members coupledtogether by connections or joints;

FIG. 2A is an enlarged, partial cross-section view of one of the tubularconnections of FIG. 1, including the radial expansion and plasticdeformation of a portion of the first tubular member;

FIG. 2B shows the radial expansion and plastic deformation of thetubular members and connection of FIG. 2A;

FIG. 3 is a schematic representation of an operating environment for abasic exemplary completion or production apparatus;

FIG. 4 is a partial, cross-section view of an expandable tubulartelescoping tool in accordance with the principles herein, showing thevarious components of the tool assembly in an axially contractedposition;

FIG. 5 is a full cross-section view of the upper guide member of FIG. 4;

FIG. 6 is the telescoping tool assembly of FIG. 4 shown in an axiallyexpanded position;

FIG. 7 is a partial, cross-section view of another embodiment of anexpandable tubular telescoping tool in accordance with the principlesherein, showing the various components of the tool assembly in anaxially contracted position;

FIG. 8 is the telescoping tool assembly of FIG. 7 shown in an axiallyexpanded position;

FIG. 9 is a full cross-section view of the upper guide member of FIGS. 7and 8;

FIG. 10 is a side perspective view of the upper guide member of FIGS.7-9;

FIG. 11 is a side perspective view of the lower guide member of FIGS. 7and 8;

FIG. 12 is a radial section view of the telescoping tool assembly atsection 12 of FIG. 7;

FIG. 13 is a radial section view of the upper guide member at section 13of FIGS. 9 and 10;

FIG. 14 is a radial section view of the lower guide member at section 14of FIG. 11;

FIG. 15 is a radial section view of the telescoping tool assembly atsection 15 of FIG. 7;

FIG. 16 is a radial section view of the telescoping tool assembly atsection 16 of FIG. 7; and

FIG. 17 is a radial section view of the telescoping tool assembly atsection 17 of FIG. 7.

DETAILED DESCRIPTION

In the drawings and description that follow, like parts are typicallymarked throughout the specification and drawings with the same referencenumerals. The drawing figures are not necessarily to scale. Certainfeatures of the invention may be shown exaggerated in scale or insomewhat schematic form and some details of conventional elements maynot be shown in the interest of clarity and conciseness. The presentdisclosure is susceptible to embodiments of different forms. Specificembodiments are described in detail and are shown in the drawings, withthe understanding that the present disclosure is to be considered anexemplification of the principles of the invention, and is not intendedto limit the invention to that illustrated and described herein. It isto be fully recognized that the different teachings of the embodimentsdiscussed below may be employed separately or in any suitablecombination to produce desired results.

Unless otherwise specified, any use of any form of the terms “connect”,“engage”, “couple”, “attach”, or any other term describing aninteraction between elements is not meant to limit the interaction todirect interaction between the elements and may also include indirectinteraction between the elements described. In the following discussionand in the claims, the terms “including” and “comprising” are used in anopen-ended fashion, and thus should be interpreted to mean “including,but not limited to . . . ”. The terms “pipe,” “tubular member,” “casing”and the like as used herein shall include tubing and other generallycylindrical objects. In addition, in the discussion and claims thatfollow, it may be sometimes stated that certain components or elementsare in fluid communication. By this it is meant that the components areconstructed and interrelated such that a fluid could be communicatedbetween them, as via a passageway, tube, or conduit. The variouscharacteristics mentioned above, as well as other features andcharacteristics described in more detail below, will be readily apparentto those skilled in the art upon reading the following detaileddescription of the embodiments, and by referring to the accompanyingdrawings.

Referring initially to FIG. 1, a string 14 of coupled tubular members isdisposed in a well bore 10 drilled through the formation 12, creating anannulus 13. The string 14 comprises a series of connected tubularmembers, such as casing joints 15, 16, 17 and 18, having a centerline oraxis 19. In some embodiments, the casing joints are secured byconnections 15 a, 16 a and 17 a as indicated to form an elongate stringthat extends to the well surface. The casing string 14 is illustrated asbeing made up of individual casing joints of approximately 40 feet inlength, for example, with a joint connection between the adjoiningcasing joints. In accordance with the principles of the presentdisclosure, the casing string 14 is to be radially expanded andplastically deformed into engagement with the surrounding well bore 10using a forging device or expansion mandrel that passes internallythrough the casing string 14 and the connections 15 a, 16 a, and 17 a.In other embodiments, the well bore 10 is cased and the string 14 isexpanded toward the casing.

Referring now to FIG. 2A, the connection 15 a of FIG. 1 is shownenlarged and in partial cross-section about the axis 19. The firsttubular member 16 includes an internal connection surface 22 at an endportion 24. In some embodiments, the internal surface 22 includesthreads. An external connection surface 28 of an end portion 26 of thesecond tubular member 15 is coupled to the internal connection 12 of theend portion 14 of the first tubular member 10. In some embodiments, theexternal surface 28 includes threads such that the surfaces 22, 28 arethreadedly engaged. The first and second tubulars 16, 15 abut atlocations 30, 32. In an exemplary embodiment, the internally threadedconnection 22 of the end portion 24 of the first tubular member 16 is abox connection, and the externally threaded connection 28 of the endportion 26 of the second tubular member 15 is a pin connection.

In an exemplary embodiment, as illustrated in FIGS. 2A and 2B, the firstand second tubular members 16, 15 may then be positioned within anotherstructure 10 such as, for example, a wellbore, and radially expanded andplastically deformed, for example, by moving an expansion device or cone34 through the interiors of the first and second tubular members. Themovement of the expansion cone 34 through the interiors of the first andsecond tubular members 16, 15 may be from top to bottom or from bottomto top. As shown, the tubular members 15, 16 are radially expandablefrom a first unexpanded position to a final plastically deformedposition.

In the embodiments just described, and throughout the disclosure herein,the wellbore or borehole described may be uncased or cased. Theexpandable tubulars may be radially expanded and plastically deformedtoward the uncased borehole, or toward a casing already in place in theborehole.

Referring to FIG. 3, a schematic representation of an operatingenvironment for a basic exemplary completion or production apparatus 100is shown. The apparatus 100 is an exemplary embodiment, and variousother embodiments of the apparatus 100 consistent with the teachingsherein are included. As depicted, a drilling rig 110 is positioned onthe earth's surface 105 and extends over and around a well bore 120 thatpenetrates a subterranean formation F for the purpose of recoveringhydrocarbons. The well bore 120 may be drilled into the subterraneanformation F using conventional (or future) drilling techniques. The wellbore 120 may extend substantially vertically away from the surface 105over a vertical portion 122, or may deviate at any angle from thesurface 105 over a lateral well bore portion 124. In some instances, allor portions of the well bore 120 may be vertical, deviated, horizontal,and/or curved.

At least a portion of the vertical well bore 122 may be lined withcasing 125 that may be cemented 127 into position against the formationF in a conventional manner. A lower portion 128 of the well bore 122 mayalso be lined with cemented casing 125. In some instances, the operatingenvironment for the apparatus 100 includes a substantially uncased, openhole well bore 120. The well bore may also include the uncased, openhole lateral well bore portion 124. The lateral well 124 may includevarious hydrocarbon producing zones 80, 82, 84, 86, 88, 90. The drillingrig 110 includes a derrick 112 with a rig floor 114 through which atubing or work string 118 extends downwardly from the drilling rig 110into the well bore 120. The tubing string 118 suspends a representativedownhole production apparatus 100 to a predetermined depth within thewell bore 120 to perform a specific operation, such as perforating acasing, expanding a fluid path therethrough, fracturing the formation F,producing the formation F, or other completion or production operation.The tubing string 118 may also be known as the entire conveyance aboveand coupled to the apparatus 100. The drilling rig 110 is conventionaland therefore includes a motor driven winch and other associatedequipment for extending the tubing string 118 into the well bore 120 toposition the apparatus 100 at the desired depth.

While the exemplary operating environment depicted in FIG. 3 refers to astationary drilling rig 110 for lowering and setting the apparatus 100within a land-based well bore 120, one of ordinary skill in the art willreadily appreciate that mobile workover rigs, well servicing units, suchas coiled tubing units, and the like, could also be used to lower theapparatus 100 into the well bore 120. It should be understood that theapparatus 100 may also be used in other operational environments, suchas within an offshore well bore.

The production apparatus 100, disposed partially in cased hole 122 andsubstantially in open hole 124, includes an upper end having a linerhanger 132, a lower end 136, and a tubing section 134 extendingtherebetween. The lower end 136 may include devices 138, 140 such as aguide shoe, a float shoe or a float collar of a type known in the art,and other tubing conveyed devices 142, 144. The borehole 124 and thetubing section 134 define an annulus 146 therebetween. The tubingsection 134 includes an interior 148 that defines a flow passage 150therethrough. The tubing section 134 may include an inner string 152with a lower end 154 that extends into a polished bore receptacle 144.The inner string 152 may be used to carry out preliminary operations,such as perforating or jetting. Alternatively, the tubing section 134does not include the inner string 152 such that the flow passage 150 isthe main flowbore through the apparatus 100. A plurality of devices 158are connected in the tubing section 134 and provide operationalinteraction with the various hydrocarbon producing zones 180, 182, 184,186, 188. The completion or production devices 158 may include seals,packers, subs, screens, blast joints and other devices used incompletion or production strings.

Referring to FIG. 4, an assembly 200 for axial expansion and contractionof a tubular string is shown. As will be shown and described herein,tubular members of the assembly 200 are configured for relative axialmovement while coupled to allow for expansion and contraction of theoverall tubular string. Thus, the assembly 200 may also be referred toas an axial expansion tool or telescoping tool. In some embodiments, oneor more of the tubular members in the telescoping tool is radiallyexpandable, as will be described more fully herein. In certainembodiments, the tubular members are radially expandable to aplastically deformed position.

In FIG. 4, the telescoping tool assembly 200 is shown in an axiallycontracted position. An upper half of the telescoping tool assembly 200is shown in cross-section, including an outer housing 220, an internalupper guide member 210 and a lower guide and seal assembly 230. Theouter housing 220 is a tubular member including an upper end 222 and alower end 224. The internal upper guide member 210 is a tubular memberincluding an upper end 212 and a lower end 214. As shown in FIG. 5, aninner surface 215 of the upper guide 210 includes one or more slots 216extending from an intermediate portion of the upper guide 210 to the end214. In some embodiments, the slots 216 are milled. In some embodiments,an axial length 218 of the slots 216 is approximately 6 feet to 10 feet,though this range is exemplary only and other lengths are contemplated.

Still referring to FIG. 4, the lower guide 230 is a tubular memberincluding an upper end 232 and a lower end 234. The upper end 232includes outer slots 236 and ribs or splines 237 for slidably matingwith the slots 216, creating the telescoping arrangement between theupper guide 210 and the lower guide 230 wherein these membersreciprocate relative to each other. In some embodiments, the slots 236are milled resulting in the splines 237. In some embodiments, the axiallength of the slots 236 and splines 237 is similar to the length 218such that a stroke 238 is created between the mating splines 237 andslots 216. The mating splines 237 and slots 216, 236 may also bereferred to as anti-rotation splines. The splines and slots are aninterlocking mechanism for axial movement and anti-rotation. In otherembodiments, the positions of the splines 237 and the slots 216 arereversed, wherein the splines 237 are disposed on the upper guide 210and instead extend into the slots 216 disposed on the lower guide 230.In some embodiments, other interlocking mechanisms are used between thetelescoping and reciprocal upper guide 210 and lower guide 230 for axialmovement and simultaneous prevention of relative rotation between thesetwo members. While rotation between the two tubular members 210, 230 inthe tool 200 is prevented, it should be understood that the overall tool200 may be rotated as part of the larger tubular string into which thetool 200 is coupled. Thus, rotating or torquing through the tool 200 ispossible via the anti-rotation mechanism that prevents relative rotationinside the tool 200.

The slidably coupled and reciprocating guide members 210, 230 aredisposed inside the outer housing 220. Disposed between the guidemembers 210, 230 and the outer housing 220 is a sleeve or layer 270. Aportion of the sleeve 270 is disposed between the guide members 210, 230over the length of the interlocked splines and slots. Another portion ofthe sleeve 270 is disposed between the lower guide 230 and the outerhousing 220. One or more sealing members or bands 239 may be disposedbetween the lower guide 230 and the outer housing 220.

In some embodiments, the sleeve 270 is a layer of non-metal materialdisposed between the metal tubulars 210, 230 and metal tubular 220 toprevent metal to metal contact between these tubulars. For example, thesleeve 270 comprises a layer of high strength, high modulus material. Inexemplary embodiments, the sleeve 270 comprises a polyurethane material.In still other embodiments, the sleeve 270 is a layer of a spray onmaterial, a bonded on (to one tubular or the other) material, a wrappedon material, or a combination thereof. In some embodiments, the sleeve270 is a nano material. In some embodiments, the sleeve 270 is acomposite material. The sleeve 270 is a lubricous, or becomes alubricous, material that provides lubricity between the metal tubularmembers. The sleeve 270 is a non-cladding material, wherein bonding orother permanent attachment between the metal tubular members isprevented. As will be further described herein, the lubricous material270 allows relative axial movement of the guide members 210, 230 and theouter housing 220 of the telescoping tool assembly 200, both before andafter radial expansion and plastic deformation of the tool assembly. Insome embodiments, the sleeve 270 also radially expands to transferradial expansion loads between the tubular member 210, 230, and betweenthe tubular members 220, 230, and act as a seal.

In some embodiments, the upper end 222 of the outer housing 220 isattached to the upper end 212 of the upper guide member 210, such as viaa hanger connection, a threaded connection or a weld. In someembodiments, the connection between the outer housing 220 and the upperguide 210 is permanent. The upper end 222 of the outer housing 220includes a connector coupled with a connector end 242 of a tubularmember 240. The connectors may be threaded to form a threaded connection225. In some embodiments, the tubular member 240 is a non expandableoilfield casing or tubing string with a premium connection. In someembodiments, the tubular member 240 is expandable. In some embodiments,the outer housing 220 is an expandable member with a premium connectionto form the connection 225.

The lower end 234 of the lower guide member 230 includes a connectorcoupled with a connector end 252 of a tubular member 250. The connectorsmay be threaded to form a threaded connection 235. In some embodiments,the tubular member 250 is a non expandable oilfield casing or tubingstring with a premium connection. In some embodiments, the tubularmember 250 is expandable. In some embodiments, the lower guide member230 is an expandable member with a premium connection to form theconnection 235. In some embodiments, the upper guide member isexpandable. A shear connection 260, such as a shear ring or shear pin,extends through the outer housing end 224 and the lower guide end 234 tosecure the assembly 200 in the contracted or closed position shown inFIG. 4. The contracted position may be maintained by the shearconnection 260 while the assembly 200 is being lowered into itsoperating position such that the assembly 200 does not expand or openbefore it is in place.

In FIG. 4, the expansion tool 200 is shown in the contracted or closedposition. When tensile and/or compressive forces are created in one orboth of the tubing strings 240, 250 due to thermal or pressure effectstherein, the expansion tool is configured to axially expand or open asshown in FIG. 6. Upon application of the axial forces from the tubingstrings 240, 250, the shear connection 260 is sheared to release thelower assembly, comprising the lower guide member 230 coupled to thetubular member 250, from the upper assembly, comprising the upper guidemember 210 coupled to the outer housing 220 which is coupled to thetubular member 240. The lower assembly is then allowed to move axiallyrelative to the upper assembly, as shown in FIG. 6 and represented bythe strokes 238, 258. More particularly, the lower guide 230 movesaxially relative to the upper guide 210, with the interlocking splines237 and slots 216, 236 sliding axially against each other whilepreventing relative rotation. The non-metal sleeve or layer 270 preventsmetal to metal contact between the interlocking and sliding splines andslots while also providing one or more of load transfer, sealing andlubricity. Axial forces applied in the opposite direction will force theassembly 200 back toward the contracted position of FIG. 4. Movementbetween the contracted and expanded positions of the assembly 200 willabsorb the axial forces that may be detrimental to fixed components ofthe well completion system, such as packers, tubing hangers or tubinganchors.

In some embodiments, the shear connection 260 is placed at variableaxial positions from that shown. Further, in some embodiments, theoriginal sheared run-in position of the assembly 200 can be any ofvarious positions between the contracted position of FIG. 4 and theexpanded position of FIG. 6. The pinned, run-in position may be closed,open, or partially open.

Referring next to FIG. 7 another embodiment is shown including atelescoping tool assembly 300 with radially expandable members. An upperassembly includes an upper guide member 310 coupled to an outer housing320 which is coupled to an upper tubular string 340. A lower assemblyincludes a lower guide member 330 coupled to a lower tubular string 350.The two assemblies are sheared connected at 360. In some embodiments,the shear connection 360 is located at other axial positions along theassembly 300, to provide various closed, open, or partially open run-inpositions. Sealing members 339 are coupled between the lower guide 330and the outer housing 320. A non-metal sleeve or layer 370 includesaxial lengths disposed between the lower guide 330 and the outer housing320, and between the lower guide 330 and the upper guide 310 at aninterlocking and sliding anti-rotation mechanism 390. As shown in FIG.8, axial forces in the tubing strings 340, 350 will cause the connection360 to shear and the upper and lower assemblies to move axially relativeto each other by sliding of the lower guide splines, as shown in FIG.11, in the upper guide slots 316, as shown in FIG. 9. In someembodiments, the splines and slots are located on opposite members, andother interlocking arrangements are used to allow reciprocatingtranslation of the upper and lower guides while preventing rotation.Such an arrangement allows rotation and torque to be transferred throughthe tool 300.

Referring to FIGS. 10 and 11, an end 314 of the upper guide member 310(FIG. 10) is configured to received an end 332 of the lower guide member330 (FIG. 11). The lower guide member 330 include alternating splines337 and slots 336. The splines 337 mates with slots 316 milled into theinner surface 315 of the upper guide member 310. A sealing band 339 isprovided on the lower guide 330 for sealing with the upper guide 310. Anon-metal sleeve or layer 370 is provided on the lower guide 330 to eachcontact with and transfer loads between the lower guide 330 and theupper guide 310 and outer housing 320.

Referring now to FIG. 12, a radial cross-section is shown of theassembly 300 of FIG. 7. The inner, lower guide member 330 is surroundedby the upper guide member 310. Disposed between the interlocking splinesand slots, as previously described, is the layer 370. The radialcross-section of the upper guide member 310 of FIGS. 9 and 10, as shownin FIG. 13, illustrates the slots 316 in the inner surface 315. Theradial cross-section of the lower guide member 330 of FIG. 11, as shownin FIG. 14, illustrates the splines 337 separated by the reduceddiameter outer surfaces 336. FIGS. 15-17 are additional radialcross-sections of the assembly 300 of FIG. 7. In FIG. 15, the lowerguide member 330 is surrounded by the upper guide member 310, with theintervening layer 370 disposed therebetween at the spline/slotarrangements. The outer housing 320 surrounds and contains the upperguide member 310. In FIG. 16, a different portion of the layer 370 isshown disposed between the inner guide member 330 and the outer housing320. In FIG. 17, the outer housing 320 is shown surrounding andcontaining the upper part of the guide member 310. As previously noted,the upper end of the outer housing 320 may be attached to the upper endof the upper guide member 310 via a hanger connection, a threadedconnection or a weld.

In the expansion tool assemblies 200, 300, an expansion device may becoupled thereto. An expansion device, such as the expansion cone 34, maybe coupled to the assemblies 200, 300 or to the tubing strings 240, 250,340, 350. Other expansion devices are known and contemplated herein.Before activation of the expansion device, the telescoping tools may besheared from their run-in positions (any one of open, closed, orpartially open) and the tubular guide members may be reciprocatedrelative to the other guide member and the outer housing to accommodateaxial loads in the tubing strings. In further embodiments, uponapplication of a hydraulic or mechanical driving force, the expansiondevice is moved or displaced through the assemblies 200, 300 to radiallyexpand and plastically deform portions thereof. As described herein,certain components and connections of the assemblies 200, 300 may beexpandable while others are not. These components may be radiallyexpandable to a plastically deformed position. The tubing strings 240,250, 340, 350 may be expandable or non-expandable. In some embodiments,the assemblies 200, 300 include seals or other members bonded orattached to the outer surfaces such that the radially expandedassemblies 200, 300 engage the seals with an existing exterior structureand provide an anchor hanger. If all or some of the tubing strings 240,250, 340, 350 are expanded, the assemblies 200, 300 may be expandedindependently of the tubing strings or concurrently with the tubingstrings. Different combinations of expandable and non-expandablecomponents and connections may be used to produce desired results.

Thus, in the pre-expanded position, the assemblies 200, 300 can supportaxial tension and compression loads in the tubular strings. Further,when all or portions of the telescoping tool assemblies 200, 300 areradially expanded, the assemblies can continue to accommodate axialtension and compression loads in the tubular strings by allowing themoveable guide member to telescope or reciprocate relative to the otherguide member and the outer housing. The radially expanded andplastically deformed tool assemblies 200, 300 retain their axialexpansion or telescoping functionality. The layers 270, 370 are providedto facilitate the retained telescoping functionality. The layers 270,370 provide lubricity between the moveable joint components, such asbetween the moveable guide member and the other guide member and outerhousing. The layers 270, 370 comprise non-cladding materials such thatthe moveable guide members are not bonded upon radial expansion. Thelayers 270, 370 transfer loads between the assembly components, such asradial expansion loads from the inner tubular members to the outertubular members. The layers 270, 370 provide sealing characteristicsafter radial expansion. The layers 270, 370 help maintain component andtool shape after radial expansion. The tools 200, 300 are re-shaped byradial expansion, and the layers 270, 370 provide a medium for retaininggeometric shape after expansion while also maintaining functionality andoperability of the relatively axially moveable members.

The assemblies 200, 300, whether radially expanded or not, by beingaxially moveable limit or remove axial load constraints within thetubular or casing string they are coupled to, such as the strings 240,250, 340, 350. The assemblies 200, 300 also support pressures in boththe pre- and post-expanded positions.

In all embodiments, radial expansion and plastic deformation of at leastportions of the assemblies 200, 300 increases the effective flow area ofthe system to enable higher injection or production rates, and decreasesrestrictions, particularly at the liner hanger, for the passage of workstrings and tools. Upon radial expansion, the assemblies 200, 300 arestill capable of accommodating axial expansion or contraction loads inthe tubular strings via the relatively moveable guide members. Further,the sleeves or layers 270, 370 transfer the radial expansion loads fromthe inner tubular members to the outer tubular members, in addition toproviding sealing and lubricating characteristics.

While the disclosure is susceptible to various modifications andalternative forms, specific embodiments thereof are shown by way ofexample in the drawings and description. It should be understood,however, that the drawings and detailed description thereto are notintended to limit the disclosure to the particular form disclosed, buton the contrary, the intention is to cover all modifications,equivalents and alternatives falling within the spirit and scope of thepresent disclosure.

1. A downhole telescoping tool comprising: a first metal tubular member;a second metal tubular member disposed in the first metal tubular memberand reciprocal therein; and a non-metal layer disposed between the firstand second tubular members; wherein the first and second tubular membersare radially expandable to a plastically deformed position.
 2. Thetelescoping tool of claim 1 wherein the first and second tubular membersare radially expanded and plastically deformed.
 3. The telescoping toolof claim 2 wherein the non-metal layer transfers the radial expansionload from the second tubular member to the first tubular member.
 4. Thetelescoping tool of claim 2 wherein the second tubular member isreciprocal in the first tubular member before and after radialexpansion.
 5. The telescoping tool of claim 2 wherein the non-metallayer is lubrication between the reciprocal second tubular member andthe first tubular member.
 6. The telescoping tool of claim 2 wherein thenon-metal layer seals between the second tubular member and the firsttubular member.
 7. The telescoping tool of claim 1 further comprising anouter tubular housing receiving the first and second tubular members. 8.The telescoping tool of claim 7 wherein the outer tubular housing isradially expandable.
 9. The telescoping tool of claim 7 wherein theouter tubular housing engages a portion of the non-metal layer.
 10. Thetelescoping tool of claim 7 wherein the outer tubular housing is coupledto at least one of the first tubular member and the second tubularmember.
 11. The telescoping tool of claim 7 wherein the outer tubularhousing is coupled to an upper tubular string.
 12. The telescoping toolof claim 11 wherein the upper tubular string is radially expandable. 13.The telescoping tool of claim 1 wherein the second tubular member iscoupled to a lower tubular string.
 14. The telescoping tool of claim 13wherein the lower tubular string is radially expandable.
 15. A downholetelescoping tool comprising: a first tubular member slidably coupledwith a second tubular member; and an intermediate layer of non-claddingmaterial disposed between the slidably coupled first and second tubularmembers; wherein the first tubular member, the second tubular member,and the intermediate layer are radially expanded and plasticallydeformed; wherein the first tubular member and the second tubular memberare relatively slidable before and after radial expansion and plasticdeformation.
 16. The telescoping tool of claim 15 further comprisingsplines disposed between the first and second tubular members to preventrotation while allowing axial translation of the first and secondtubular members.
 17. The telescoping tool of claim 15 wherein afterradial expansion and plastic deformation the intermediate layer providesat least one of load transfer, lubrication and sealing.
 18. A method ofradially expanding a telescoping tool comprising: disposing a layer ofmaterial between an inner tubular member slidably coupled to an outertubular member; radially expanding and plastically deforming the innertubular member into the layer of material; transferring the radialexpansion load to the outer tubular member using the layer of materialto radially expand and plastically deform the outer tubular member; andafter radial expansion and plastic deformation of the inner and outertubular members, sliding the inner and outer tubular members relative toeach other.
 19. The method of claim 18 further comprising using thelayer of material to prevent cladding of the inner and outer tubularmembers in response to the radial expansion and plastic deformation. 20.The method of claim 18 further comprising moving an expansion devicethrough the inner and outer tubular members.